Best Tugs for Stacking Hangars: The 2025 Buyer's Guide

A Gulfstream G650 owner called last week, frustrated after being told his FBO was out of hangar space. But looking at the hangar photo he sent, three empty spots were clearly visible. The problem wasn't space; it was how they were moving aircraft.

Conventional towbar tugs limit hangar stacking efficiency, leaving money and space unused. Modern towbarless and remote-controlled tugs can increase hangar capacity by 40-60%, sometimes doubling it. Here's what actually works in 2025.

The Reality of Hangar Layout Constraints

Before diving into equipment specs, understand that not all hangars are created equal. Your capacity gains depend heavily on:

Hangar Design Factors:

• Door configuration: Single vs. bi-fold vs. sliding affects traffic flow
• Structural columns: Limit positioning options regardless of tug type
• Ceiling height: Varies from 20-40 feet, affecting tail clearance
• Floor conditions: Smooth epoxy vs. textured concrete affects tug performance

Aircraft Mix Considerations:

• Size variation: Mixing PC-12s with G650s requires different spacing strategies
• Wing clearance: High-wing vs. low-wing aircraft have different requirements
• Tail height: Affects row spacing and overhead clearance
• Access needs: Maintenance vs. storage affects positioning requirements

Operational Constraints:

• Peak period congestion: Rush hours limit movement efficiency
• Maintenance scheduling: Aircraft undergoing service need different access
• Customer preferences: Some owners pay premium for specific positioning
• Safety clearances: Insurance and regulatory requirements can't be ignored

Why Your Tug Choice Matters

A five-unit fleet of electric tugs saves approximately $13,000 annually in fuel costs alone. But that's pocket change compared to the real money: hangar revenue. One FBO owner recently said: "I didn't need to build another hangar to increase my revenue—purchasing the Mototok did that for me."

Traditional tugs need wide aisles for maneuvering due to physical constraints. Towbarless tugs with zero-degree turning can park a Citation against the wall with inches to spare, translating to 2-3 extra aircraft per hangar at well-run operations.

Three Tug Types That Transform Your Hangar Operations

1. Towbarless Electric Tugs (The Workhorses)

LEKTRO's 88 Series dominates this category with proven track record across major FBOs. With capacity ratings up to 120,000 lbs (verify with manufacturer for your specific aircraft), it handles everything from King Airs to large-cabin jets. The hydraulic cradle scoops up the nose gear in 15 seconds—no bars, no hassle.

Key specs that matter:

• Weight capacity: Generally sized for 10-15% of aircraft MTOW (consult manufacturer specifications)
• Turning radius: True zero-degree turning radius for tight spaces
• Battery life: 8+ hours for busy operations
• Charging time: 6-8 hours for full charge
• Maintenance intervals: Monthly inspections vs. daily for diesel units

A towbarless tug positions a Gulfstream G550 with surgical precision—no aisles needed

2. Remote-Controlled Tugs (The Game Changers)

Mototok remote-controlled tugs excel in tight quarters where precision matters most. An operator can walk around the aircraft while steering via remote, parking jets in spots that would be impossible with a ride-on tug.

Multiple FBOs have achieved 40-50% capacity increases with proper remote-controlled tugs. At typical hangar rates of $2,500-4,000/month per spot, each additional aircraft generates $30,000-48,000 annually. The math becomes compelling when you're turning away customers due to "full" hangars.

3. Heavy-Duty Specialists (For Mixed Fleets)

If you're handling everything from PC-12s to BBJs, LEKTRO's 8950 Series (210,000 lbs capacity) is your Swiss Army knife. It's the first TLTV certified for new Boeing aircraft, meaning you won't damage that $80 million asset while maximizing hangar density.

Electric vs. Diesel: Financial Comparison

Environmental benefits aside, the financial case for electric tugs is compelling:

Operating Costs (Daily):

• Electric tug: $5.79 (electricity + minimal maintenance)
• Gas tug: $13.00 (fuel + routine maintenance)
• Annual savings per tug: $2,628

Hidden Costs to Consider:

• Electric: Higher upfront cost ($15,000-25,000 premium), charging infrastructure
• Diesel: Oil changes every 100 hours, transmission service, exhaust ventilation systems
• Training: 2-3 days for operators on new equipment ($1,500-2,000)
• Insurance: Some carriers offer discounts for electric GSE

Electric tugs also eliminate oil changes, transmission repairs, and diesel exhaust in your climate-controlled hangar—something your maintenance team will appreciate.

Five-year total cost of ownership: Electric tugs win by a landslide

Safety Features That Prevent $500K Mistakes

One damaged nose gear on a G650 costs more than a fleet of premium tugs. Modern units include:

• Automatic weight sensing (prevents overloading)
• Hydraulic nose wheel fixation (no slippage)
• Obstacle detection with auto-stop
• Zero emissions for enclosed spaces

An important note from FAA Advisory Circular AC 00-34B: Match your tug capacity to aircraft weight properly. An oversized tug can damage nose gear just as quickly as an undersized one.

Implementation Considerations

Before you order that shiny new tug, consider these operational factors that can make or break your investment:

Hangar Layout Constraints:

• Door height limitations (some tugs add 2-3 feet to aircraft height)
• Floor loading capacity (electric tugs are heavier)
• Turning radius requirements vary by hangar design
• Electrical infrastructure for charging stations

Training and Certification:

• 2-3 days minimum for operators to achieve proficiency
• Different handling characteristics require adjustment period
• Some insurance providers mandate specific training programs
• Backup operators needed for continuous coverage

Maintenance Considerations:

• Monthly hydraulic system checks vs. daily diesel maintenance
• Specialized technicians for electronic components
• Parts availability—electric components vs. standard mechanical parts
• Warranty coverage: typically 2-3 years on major components

Integration Timeline:

• Month 1-2: Equipment delivery and setup
• Month 3-4: Staff training and initial operations
• Month 5-6: Full efficiency achieved
• Expect 10-15% productivity dip during transition

Emerging Technology Trends

The electric aircraft tug market is growing at 5.1% annually, and three technology trends are driving this growth:

1. Semi-autonomous systems: TLD is testing tugs that remember hangar layouts and park aircraft automatically
2. 5G remote operation: Control tugs from anywhere on the airport
3. AI positioning: Computer vision that maximizes space utilization automatically

Realistic ROI Calculation

Let's break down the realistic math for your operation:

Phase 1: Assessment (Month 1-2)

1. Count aircraft currently in your hangar
2. Map your hangar layout and identify constraints
3. Calculate realistic capacity increase (20-50% depending on current efficiency)
4. Factor in aircraft mix—different types have different space requirements

Phase 2: Implementation Costs

• Tug purchase/lease: $80,000-150,000 per unit
• Facility modifications: $5,000-15,000 (charging, ventilation)
• Training: $1,500-2,000
• Insurance adjustments: varies

Phase 3: Payback Timeline

• Conservative estimate: 18-24 months
• High-density operations: 12-18 months
• If turning away customers: 6-12 months

Factor in ramp-up time (3-6 months), seasonal variations, and maintenance downtime. Most successful FBOs see full ROI within 24 months, sometimes sooner if they're consistently turning away customers.

Ready to Stack Smarter?

Download our free Hangar Capacity Calculator to see exactly how many more aircraft you could fit with the right tugs. Includes tug recommendations based on your fleet mix.

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Same hangar, 50% more aircraft—just by upgrading to towbarless tugs